Mold, die, and the like and method of making the same



2 Sheets-Sheet 1 BEST AVAILABLE COPY C. P. MADS EN MOLD, DIE AND THE LIKE, AND METHOD OF MAKING THE SAME Mmh '2', 1926.; r

. Original Filed June 25, 1919 951, ii 6mm BEST AVAlLABLE COP\ March 2, 1926. 1,515,122

C. P. MADSEN u'oLn, DIE, AND THE LIKE, AND METHOD OF MAKING THE SAME Original Filed n 1919 2 Sheets-Sheet 2 m awvemoz abhor mugs Patented Mar. 2, 1926.

BEST AVAlLABLE coP UNI STATES 1,575,122 PATENT OFFICE.

CHARLES P. MADSEN, bF-NEW-YORK, N. Y., assfenon T0 MADsRnEL CORPORATION,

' OF NEW YORK, N. Y., A coRPoRA'rIoN OF NEW YORK.

Mo Ln mR, AND THE IKR AND METHOD OF MAKING THE SAME.

Application ii1ed J 11iie 25, 1 9"19, Serial No.306,597. Renewed May 7, 1925.

To all whom it may concern.

Be it known that I, CHARLES P.'MA nsEN, a citizen of the United States, and a resident of the city, county, and'State of New York, have invented 'anfImprovement in Molcls, Dies, and the like and Methods ofMaking the Same, of which'the following is 'a's'pecificatioiL I My invention aims to provide forms, molds, diesa nd the like of a new and superior type especially for forming or shaping materials which in their natural "state are more or less plastic or jwhiclrmay-be rendered plastic by such agents. as solvents scribed for purposes of illustration and shown more particularly as used in connection with one illustrative embodiment of mold;

Figure 2 is a longitudinal section of the mold diagrammatically shown during the process of production in Figure 1;

Figures 3 and 4 are cross-sectional and perspective views, respectively, of another form of mold during one stage of itsproduction;

Figure 5 is a cross section of such mold during another stage of its production;

Figure 6 is a top elevation of such mold when completed and assembled;

Figures 7 and 8 are longitudinal and cross sections of another form of mold.

The materials customarily available for making molds and the like are poorly adapted for the purpose, especially where chemical reactions taking place at high temperatures are employed during the process of molding, and the cost of making molds from the usual materials is so' high as to very much limit their use. This is especially true in moldsfor die casting and glass working. Molds made of ceramic materials, which have been employed to some extent in forming glass articles, are too frail, and.

those out "from steel 'or alloys by tool-working means, as in this way a high degreeof accuracy is obtained. But even these molds are short-lived because they soon lose their accuracy by destructive" oxidation or other chemical action, and their cost is prohibi tive for many purposes.

'I- have discovered: that the nickel metals which I mean nickel,.or cobalt,

or alloys'containing either nickel or. cobalt or both of these metals,'"l5ut more par-I ticularly substantially pure nickel, possess superior and highly desirable properties for the desired purpose; Nickel, for example, is not only refractory, but'I have discovered that it possesses a very. valuable oxidation characteristic. Its surface oxidation is constructive for the desired purpose, rather than destructive. The'oxide coating which forms on nickel when subjectedtohigh temperatures in air, for example, possesses the mechanical propertiesof a metal, is very hard andfirmly adherent. It furthermore forms with a glossy surface, even though the original surface of the nickel is not polished, and is so thin and uniform in thickness that it does not appreciably change the dimensions of even very small lines or markings. After this oxide filmhas formed, it arrests any further and deeper oxidation, and also resists to a remarkably high degree other chemical action. It furthermore possesses the valuable property of very effectively pre-. venting alloying of other metals with the nickel when brought .in contact with it in a molten state, and also prevents the adherence of molten or hot glass and other materials.

I have therefore conceived the idea of providing molds made, for example, of nickel or of a nickel alloy, with an oxide coating before using the same, and I find that a. much more durable and highly useful mold is made in this way. This coating may be obtained chemically, .as for instance, by treatment with a 'hypochlorite. This or other oxidizing means may be used also to enable the deposited metal to receive an molds=by-:tool-wonking means, andsis even moreditiicult-and expensive to work by 'cutting thanis tool steel. iThe-useof molds cut fromksolid blocks of -nickel :is "therelign'e limited to the forming of materials which,

" either because :they' can not I be handled in any oth'erkind 0f-a imeld or-tor; other reason, will-" bearltheadditional cost of the cut nickel 'm 'i i I? have therefore; conceived. the idea of fabricating-nickel :or nickel alloy, {molds ,for

example, by :Emean's -.-of an. select'rodeposition process analogous tothatEdisclosedfln :my cope'nding uapplicationssiserial ylNo. 254,793, filedkseptemberrlt),r1918, Serial No. 2$ 7,f(;23,

filed May 1919, and .lfifin'd that the articles produceduby tlrisuprocess are usefully different from iand far s'up'erior .for the purpose to: those 'obtained from nickel I anade 5 by"tool-cutting imea'ns as well as being cheaper, and :thiatnew .r and unexpected: ;resuits are obtained: by the; use of the elect-rodepositedunateria'l.v I It :is [chemically more iner't" an'd 'has =a =higlier 'imeltin'gpoint. Furthermore, the io'xide lfilmf which may be formed "upon 'it; :is bette'r for the desired purpose. I It is thinner, more flexible, and finer *iri textureuwltis ofidiil'er'ent color than that for-med on I nickel -.:made by .the ordinary metallui'gical or heat -=treatment methods. Ihe =1 at-ter is violet to. dark indigo, while 5 the electrolytic nickel metal 1 forms an oxide yellow' to biownin color. Molds made ot'electrol-ytic nickel by'iny process, therefore,=la'st ionger'than even those-cut from solid nickel-blocks, andxpossess. other 'unexpected and important advantages set'forth below, 7 v

Electrodeposition is an idealmethod-of making a moldof intricate configuration or containing fine lines, but'heretofore,.as far as Iain aware, no process has'beenknown for electrodepositing metals having-the necessary properties for the purpose. Moreover, of the refractory metals, only nickel and cobalt canto 'my'knowledge, be electrodeposited at all, and the ordinary deposits of' 'these'm'etals'are porous and pitted, and such deposits are, in addition, so brittle and develop such -strains during =electrode'position that they'can be-deposited' only in' extremely-thin layers which; are-not of a truly 'nietal character.

The nickel or nickel metal made by my area '"dbeEsT AVAlLABLE coP\ process, is therefore, not only usefully different torfthei} purpose fro'm that made by heat treatment means, but it is also dif- Tfiom that made by old electrolytic ineans in that it 'conibines a degree of inalleability not possessed 'by electrolytically deposited nickel as hitherto made with new characteristics named above "and highly usefor the desired purpose. 7 y

In preparing the niol'dsboinp rising the herein described illustrative embodiments of my invention, may use, an electrode'position bath ot, the following composition: nickel sulphate, -240 nickel chloride, 2mg, *boric acid, l0 ,g.;=water, 1 liter.

tmperature of about i30 Except for the addition of boric acid, as sateen above, the-bath should be neutralf The anodepinay, consist of: cast; orgro'll'e'd nickel, and jthe -.ca thode:;of, the (if pattern of whichathegdepositis to beinade.

!Duri-1 1g deposition ;the cathode on which the nickel ,is being eleetrodeposited, is inter: mittently-or periodically exposed to a gaseons n1edium,=such' as the air, as by removal h'omthe. bath or otherwise. The 'time dur-j ingwhich the cathode and the electrode positeid nickel carried by itare kept out of the bath should be more than what I term the f minimum for hydrogen dissipation period, ,which gis necessary to permit the hydrogen,deposited with the metal to be'dissipated or removed by contact with the sur rotmdinggaseorm unedium, such as: the air. This jmin imr un., hydrogen dissipation period ma'y -be readily determined by trial -and -experiment and is generally greater-than about one second, usually two seconds. I

-T he :time 'during which the cathode and the deposit carried by it are kept out of the bath should not, however, exceed what '1 term the maximum or critical or separable deposit period, which, in the case heregiven, is from about (3 vto 16 seconds, by which I mean that if the time during which the cathode and its deposit are kept out of the bath exceeds the said fmaximum. or critical or separable deposit .period, on restoring the cathode and its deposit to the bath, the succeeding deposit will not be adherent but will separate orbe jeasily separable from the previous deposit. This results in a laminated, weak metal, a condition which is obviously to be avoided, where a sound unitary metal is desired. Y

The frequency-of removal or exposure frequency ;.p eriod is determined by the factors of deposition which influence hydrogen'liberation, such as the degree of exactness ofneutrality, current density, and tem- 11 rat=ure. I have-found that. in the bath here described by way of example, and oper- 7 Lthis bath is 5 preferably operated at 4 a ating at. a temperature of about; 130. F., and with a .current density of about 10 amperes per square decimeter,. this period maybe from 1 to 2 minutes.- 1. v y

In .order, moreover, that.;-the electrodeposited metal, such :asthe nickel-in the example given, may notonly be dense, regu-, line and .free from pores-and hydrogen,- but in order also that said metal shallrbe free .from what are known as pits -"in.the art of the depositionof the ..nickel-metals, I add to the bath, preferably befores'tartin'g the electro-deposition, 5 quantity of finely divided nickel :hydrate, preferably freshly precipitated nickel hydrate-:(NiO H and probably existing i'n a fcolloidal condition, which nickel hydrate remains in suspension in. the bath during velectrodeposition. -Whilethe quantity; ofhydratel 'so: added..may vary within considerable limits, I prefer to add from 1 to 5 grams, generally *1 gram, of said colloidal nickel'hyd-rateto each literof-bath solution:

I have discovered that by. adding to'the bath certain salts, ;such as ;the sulphates, of the alkali' metals, preferablysodium, finely divided or: colloidali. nickelwhyldrate is 3 produced and :held in :shspensionvlin the bath. This freshly' 'and continuously. produced hydrate replenishes the-"hydrate. which during the operation of thebath aggregates or for other reasons goes-outz-of :suspension. and drops-t0 the bottom: of the baths; :Suchsalts have further i beneficial" effects 5 and greatly --improve theoperation of ithebath and the character ofthe deposits-formed. JFor'this purpose may add; varying amounts, such as from about 1 :to about 10wgrains, preferaof bath'solutiorri v l Theaction of' he colloid-producing substance, such as thesodium sulphate, described above, is to produce by and during electrodeposition, some caustic soda or sodium hydroxide. The caustic soda or sodium hydroxide thus produced, by; interaction with the nickel salts present in the bath, such as the nickel sulphate, generates finely divided or colloidal nickel hydrate which remains suspended in the bath. --The interaction at the same time-regenerates the sodium sulphate. The sodium sulphate or'its equivalent also acts to assist the deposition and to improve the character of the deposit, which factors are also further assistedby the initial addition of nickel hydrate in finely divided or colloidal condition to the bath.

In Figure 1 is shown, diagrammatically, the vat 5 in which the bath Gis contained. The anode isindicated at 7, the form or pattern at 1, and the deposit at 1. Any suitable means, diagrammatically indicated at 8, may be employed for intermittently or blV '1 gram, 'of sodium sulphate for "each liter periodically removing the form or pattern,

carrying the deposit, from the-bath.

3EST AVAILABLE COPY The nickel which results from the electrodeposition process set forthabove and which is one of the nickel metals of which the moldsadescribed herein may be made, is dense, reguline, homogeneous, malleable and ductile. The new nickel herein described is substantially free from-pores and pits and contains no appreciable amount of hydrogen The nickel herein described differs in character from the nickel obtained by the usual metallurgical processes in that my new nickel is free from the usual poisonous contents such as sulphur, silicon,arsenic, carbon, carbides, oxygen, and other gases, and oxide containing compounds, generally present in metallurgicaljnickel and rendering the same imperfect andmore difficult to work. v 1

Furthermore, my new nickel is to be fur ther differentiated from the ordinarynnetallurgical nickel in th t ithas a finer and more even grain than such metallurgical nickel, as is shown by metallographic micro photographs. It is also considerably purer than such metallu rgi ;al nickel, resists chemical action betterand has ahigher melting point.- 1 r It is, of course, to be understood that wherea depositof; cobalt,-having the foregoing desirable properties, is desired to be produced, a cobalt anode isjused inplace of the corresponding nickel vcompounds. \Vhere alloys of either nickel or of cobalt or'of both'of these metals are desired to be produced, meansanalogous to the means herein set forth for the deposition of nickel and of cobalt in the desiredcondition and having the desired properties'may be employed.

Among the herein described illustrative embodiments of my invention may be mentioned a mold having merelya coating of nickel or of a nickel metal for its forming surface, and also a mold made entirely by deposition. In the case of very large molds, where great accuracy is not required, it may be desirable to make a mold of another metal, such as iron or bronze, and then give it a dense, malleable coating of nickel by my deposition process, which coating may subsequently be oxidized when the purpose for which the mold is required makes this desirable. Such a mold maybe readily cut, chased or hammered to obtain the necessary detail, which cannotbe done in the case of nickel deposited by the prior methods.

I prefer to make most molds directly by deposition, however. This embodiment may be carried out by depositing nickel or the nickel metal by my process upon a properly prepared replica of the object. This may be the original object, a wood or a plaster of Paris pattern, or a plaster of Paris or a metal cast. If the pattern is of non-conducv ing relatively flat objects in whicha'nfa'cvided with a rim "to a *lfeighv representing the thiekiiess l f the desired cast; They. may then either' be ln'eunted eo-that'theedges of the rim wiu be qevel and tlieeffeet or gravity depended upon for causing tlie liack 'oftlh'e object td beeome' levd iffeatinia'fluid ondition, or whey ueed-as inserts in sand erethe'r meld in which case the baek btE the' cafifs'ting- 69hr b'e ='="sha.p'ed by' i the I "in'g -'sma-ll *jxiietal fili ree castings, 's'iiehh's are'i1ed'on t'rnarriehta'hsilver tablewere; and '6h cash?regiter's; etegthe Y melds may not be backed by sand or other investment, "hut referablysqn16unted that they Ihay IIie heateii-WO aqiigmeinpemture. In this manner the; thin portione "of l th cast will? flow readily and eastiiigs ean' be'finajde mueh thihneffl an woul d -etherwi e be pes- A'n i illustrative *eifibedi'meiit of n iy invention is' 'shovv'h in 'Figl'ires' I- andJQ 0f the drawing, {the irio'ld shown axle-rein being in tended 'fdr' 'ferrifi'fig' materials which d not shrink appretiiably '-"duri'1ig ifermatien, Y but which must be formed on all surfacesu Su'ch materials, for 'Fifi'stan'ee', *inclhde fc'e'rtain metalmlloys, glaspeellu-loid err-d rr'lbber; -1 may niake tlri type 50f 'jr 'eld espeeially if 1561' 1 large object's', by* depaiting=the niekel or iiieliel' -meta-l over substantially th'e entire surface bf th article, repliea 'or piattern If and; then sawing thefwhole 'iinto tivo or '11iore pa1-ts,=' as 2- a1'1'd 3.' The-parts may then be hifiged I tOg'eth-"Qr, as at 4, or ;otherwise inade to :1 re isten-Molds of this type for smaller artic e's or -in ',ca'ses where the width of the "saw but} would serie'us'ly alter the dimensions may 'be In'ade so as to' conipensate fo'r-the 'Width of the'saw but-by making the pattern large enough as by first cutting it in two -"and inserting a; piece equal to the combined width of two cuts.

I prefer 'in' most-=cases, however, "to pro- 'duce=m'0lds of this type, when required-to be in'tivo'or more parts in the' m'an'ner diagrammatically illustrated Figures "3, =4, '5 and 6. To do this, the objeet'o'ripattern is fir-st marked;'- as at 1 1; to'i indicate' ther lines of separatidn of thesevera-l partsrci'n which the-mold is to "be'i'm'ade in oi derto: enable was er;

the cast 'for'm'ed in the mo1d=1to be removed. Bart of its surface, ias the 1 portion 'A, may then-be embedded inrplaster of Parisor'vvax 12 to a c0nsideralile'=thickness, Whicheplaster of P-aris Or 'vVaX :is formed '-so thatiit provides a border- F13 r'of appreciable Width substantially at right aHgles to a the esu'rface of the obj'e'ct. A This *b'or'de'r may be alft iplain', but ;'preferably has- Fridges or indentations mieh as the dhannel'l 3 Iff a ouririgiopenihg nra'ohetfor i-riserting material into fihe 'In'old *zwhen z'assenible'd wlS desired, this be made by .pla'ei-ng either a fhalfsj cylihdr 'o'r s'a-flralf .truneatedudone -15 on' gthe"desifdipoftionzofthe wax (border. The border 5 is mow antalized to freeeive 5 a deposit @for' a ipredetermined 1 distahcefi be 3 6ml the groove E14,; 'vvhi'ch fiepos'it dwilli'be integral with-that made: on the ex o edtign "of theeufface of lthetlobj ect or; pattern 10. iThisepatt-ern :i's, sof course, tififnbn me'r tailic,- treated 1 to rrece-iveiai deposit? (if metallic, it *is treated to receive amcmad- 'lierentdefidsit. Theafonn or lpatte'rn lO' is'zthenr-manipw lated in the. electrodepositiontp rocess'. as set forth: above? in? cbniiectibn with the form er pattern '21 'shown sin Figuresband: 2. Y jKVhenitheg depositdias'r-been r'formed'lto? the desired 't-hi'kness,: the Whole isreinov-edxfrom the bath? anddthe plaster or- 'wax P embedding lmaterial is theniremoved. 1 I I flhenuterre'xposd :surfacea16r: of the: mold :porti'o n ll 6; :is.*.n0' 'w etepped bffwlor. 'covered by means: of an insulating 1 material: such; as Y c'ell uloid, as i indicated art 5 l7-,-toi'p revent I the same fre'm receiving any further deposit. The rigid flange :18; is now'ftreatedrto; receive 'a nen ad-herent;deposit;ras byebeing oxidized, for example. The form 10, tvith -the,--por- -tion 'A enowwexpo's'ed 'ahd'a the -ip'ort-io n 13' covered J- ith the mold -;'porti0n .16, is now returned to the-bath;to receive-a deposit 1 of the characteraalready' described on the portion :A. This deposit will. i have .-a recessed er channelled- :fiangeq3'ortion '19 :anda 1nain portion ,20. 1-11.:the depression :21'made;;by the' half truncated ccone 15 :in the first de- :p0'sit"an entire -truncated:.c0iie of the same diameter is inserted previous to 2 making. the second: deposit, =1 and inthis Way the entrance hol'e 22 for themate'rial tobe formed is pro- .vided l Obviously-fan analogous mode :of '.procedure 1 may l'be-i; adopted where: the 1 mold -is to consist'of more-than two,- such-as'three, four or morezlparts.

It is obvious' that a the variousdeposited parts of a -mold made inthis manner will not' only registenebut will reproduce the dimensions andmarking's of the originallob- 'ject'with aihigh-degree of accuracy. Such deposits. may ,ibe-made' heavy enough .to "withstandrthe :pressures' needed for most purposes,- but where very high pressures -bakelite and condensite.

are to be used, they can be backed up by casting other metal, as bronze, around them, or by hard soldering them into a pressed steel form or cast iron block. In other cases, however, their thinness is an advantage, and in molding materials which must be formed very hot and allowed to cool before removal, as in the case of casting metals, a new result may be obtained. Since these molds'may be heated and cooled quickly, they may be heated to a temperature close to the melting point of the metal and then allowed to cool with the cast. In this manner metals having a considerable temperature coeflicient of expansion may be cast which now are difficult to cast in steel molds because it is impractical to heat such molds sufiiciently.

This type of mold is also advantageous without any backing for making what are known as slush'castings. This kind of casting consists in pouring molten metal into a mold and swishing it around until a shell of the desired thickness has solidified and then pouring the balance out. Molds made of nickel metal by my process are desirable for this purpose because they will cool off faster than a solid block; but their chief advantage is that because of their relatively uniform thickness the heat radiation will be practically uniform and the metal cast will solidify to a uniform thickness in all portions. 1

Such molds, especially when used for metal casting and glass forming, may to advantage be previously coated with an oxide film. Molds so coated are very durable for forming both metals and glass, and I find that many alloys can be cast in them which can be made in metal molds only with great difliculty, as brass and aluminum.

Still another embodiment of my invention is illustrated in Figures 7 and 8. This type of mold is intended for forming materials which shrink considerably during the process of forming them. Examples of such materials are clay, as used for making porcelain goods, and the various electrical insulating compounds, such as gummon, One portion at least of such molds must be capable of moving with relation to the other portion or portions, without letting any material escape,

and usually a higher pressure is used than in the case of ordinary casting.

Molds of this type are, therefore, required to be very heavy and are usually made in at least three parts, namely, a tube 30 which is an elongation of the sides of the object, a bottom plate 31 whose top surface contains the configuration of the bottom of the object, and a plunger 32 which moves in the tube and whose bottom surface contains the configuration of the to of the object. In operating such a incl the tube with its bottom plate facing upwards is placed on the platen 33 of a hydraulic press and the material, usually in a powdered form, inserted. The plunger is then inserted and the whole subjected to pressure. The object is removed by means of a knockout arrangement in the press, of the usual type and not deemed necessary to show here.

In making molds of this type, deposits of nickel metal are made by my process to the desired thickness on the top and bottom faces only of the object or pattern. These are then mounted, either mechanically or by hard solder, on other pieces of metal to make the bottom plate and plunger, as indicated at 31 and 32.

The side or tubular portion 30 of the mold is deposited on a separate or second form or pattern which is an elongation of the sides of the object which the mold is intended to shape. For most purposes this tubular portion may be deposited heavily enough without reinforcement, although it maybe more economical in certain cases to reinforce such tubular portion by steel or other tubing of comparatively thick walls as the tube SOshown in Figures 7 and 8.

Itis, of course, ,to be understood that my invention is not to be-limited to the particular forms thereof here shown and de scribed for purposes of illustration only.

\Vhat I claim is:

1. As an article of manufacture, a mold, die or the like comprising a non porous. malleable, nickel-containing metal provided with a dense, hard, adherent coating of an oxide ofnickel.

2. As anarticle of manufacture, a mold, die or the like comprising non-porous, malleable nickel provided with a dense, hard, adherent coating of an oxide of nickel.

3. As an article of manufacture, a mold, die or the like comprising a non-porous, electrodeposited, malleable, nickle-containing metal provided with a dense, hard,

adherent coating of an oxide of nickel.

4:- As an article of manufacture, a mold, die or the like comprising non-porous, electrodeposited, malleable nickel provided with a dense, hard, adherent coating of an oxide of nickel.

5. As an article of manufacture, a mold, die or the like comprising a nickel-containing metal provided with a dense, hard, adherent coating of an oxide of nickel.

6. As an article of manufacture, a mold, die or the like comprising nickel provided with a dense. hard, adherent coating of an oxide of nickel.

7. As an article of manufacture, a mold, die or the like comprising a non-porous, malleable, nickel-containing metal provided with an oxidized surface.

8,. As an article of manufacture, a mold,

BEST AVAiLABLE COPN 

